A double-station internal gear generating and grinding machine and a grinding and grinding wheel dressing method thereof

Abstract

This invention discloses a dual-station internal gear generating grinding machine and its grinding and grinding wheel dressing method. The grinding machine includes a bed, a grinding wheel processing unit, a workpiece exchange turntable, a grinding wheel dressing mechanism, and an automatic workpiece allowance allocation mechanism. The grinding wheel processing unit includes a grinding wheel oscillating turntable and a grinding wheel spindle. The oscillating turntable drives the grinding wheel spindle to oscillate, causing the grinding wheel axis to intersect with the workpiece axis. Two sets of workpiece spindles are installed on the workpiece exchange turntable, and the two sets of workpiece spindles are exchanged between the grinding station and the loading / unloading station by the rotation of the turntable. The grinding wheel dressing mechanism is used for in-machine dressing of the grinding wheel. The automatic workpiece allowance allocation mechanism is used to detect the workpiece grinding allowance and allocate grinding feed parameters. During grinding, the grinding wheel is located inside the internal gear workpiece, and the grinding wheel spindle, workpiece spindle, radial feed axis, and axial feed axis are linked to achieve internal gear generating grinding. This invention can improve the processing efficiency and accuracy of internal gear rings and improve the NVH performance of gear transmissions.

Description

Technical Field

[0001] This invention belongs to the technical field of gear processing machine tool equipment, specifically relating to a dual-station internal gear generating grinding machine and its grinding and grinding wheel dressing methods. Background Technology

[0002] In recent years, with the development of reducers in the new energy vehicle and robotics industries, the precision requirements of transmission components such as RV reducers and planetary reducers for internal gear rings have been continuously increasing. As a result, the demand for machine tools for high-precision machining of internal gear rings has also been increasing.

[0003] Traditional grinding of internal gear rings mainly employs the form grinding method. This method typically only allows for tooth-by-tooth machining, resulting in low efficiency and hindering mass production of internal gear rings. Furthermore, the tooth surface texture formed by form grinding is often characterized by regular vertical lines, which can negatively impact the vibration and noise performance of gears in high-speed meshing conditions, such as in new energy vehicle gears or robot reducers.

[0004] In addition, existing internal gear processing equipment also suffers from problems such as difficulty in parallel loading and unloading of workpieces and grinding, insufficient flexibility in grinding wheel dressing, and reliance on manual experience to allocate workpiece grinding allowance. These issues result in long processing cycles and poor processing consistency, making it difficult to meet the automotive and robotics industries' demands for high-precision, high-efficiency, and low-noise internal gear processing.

[0005] Therefore, it is necessary to provide a gear grinding machine and processing method that can achieve high-precision generating grinding of internal gears, dual-station alternating processing, on-machine dressing of grinding wheels, and automatic allocation of workpiece allowance. Summary of the Invention

[0006] The purpose of this invention is to provide a dual-station internal gear generating grinding machine and processing method to solve the problems of low efficiency in existing internal gear forming grinding, difficulty in parallel loading and unloading of workpieces and grinding, insufficient flexibility in grinding wheel dressing, and poor consistency in grinding allowance distribution.

[0007] To achieve the above objectives, the present invention provides a dual-station internal gear generating grinding machine, comprising a bed, a grinding wheel processing unit, a workpiece exchange turntable, a grinding wheel dressing mechanism, and a workpiece allowance automatic distribution mechanism; The grinding wheel machining unit is mounted on the bed. The grinding wheel machining unit includes a grinding wheel oscillating turntable and a grinding wheel spindle mounted on the grinding wheel oscillating turntable. The grinding wheel spindle is used to mount the grinding wheel, and the grinding wheel oscillating turntable is used to drive the grinding wheel spindle to oscillate so that the axis of the grinding wheel and the axis of the workpiece form a cross angle. The workpiece exchange turntable is mounted on the bed and arranged opposite to the grinding wheel processing unit. The workpiece exchange turntable is equipped with a first workpiece spindle and a second workpiece spindle. The workpiece exchange turntable can rotate to allow the first workpiece spindle and the second workpiece spindle to exchange between the grinding station and the loading / unloading station. The grinding wheel dressing mechanism is used for in-machine dressing of the grinding wheel. The automatic workpiece allowance allocation mechanism is used to detect the grinding allowance of the workpiece and allocate grinding feed parameters according to the detection results.

[0008] Furthermore, the grinding wheel machining unit also includes a slide plate and a column. The slide plate is movably mounted on the bed along the Y direction, the column is movably mounted on the slide plate along the X direction, and the grinding wheel oscillating turntable is movably mounted on the column along the Z direction, so as to drive the grinding wheel to achieve linear coordinate movement in the X, Y and Z directions.

[0009] Furthermore, a support column is provided in the center of the workpiece exchange turntable, and the first workpiece spindle and the second workpiece spindle are symmetrically arranged at 180° on the workpiece exchange turntable and located on both sides of the support column, respectively.

[0010] Furthermore, the grinding wheel dressing mechanism is installed on the workpiece exchange turntable. The grinding wheel dressing mechanism includes a dressing spindle oscillation mechanism and a grinding wheel dressing spindle. The dressing spindle oscillation mechanism is installed on the outer wall of one end of the support column, and the grinding wheel dressing spindle is installed on the dressing spindle oscillation mechanism.

[0011] Furthermore, the grinding wheel dressing mechanism also includes a dressing diamond pen, which is installed on the side wall of the grinding wheel dressing spindle and is used to dress the outer circle of the grinding wheel.

[0012] Furthermore, the automatic workpiece allowance distribution mechanism includes a support base, a rotary swing arm, a radial telescopic arm, a vertical moving rod, and a detection sensor. The support base is mounted on the machine bed, the rotary swing arm is rotatably mounted on the support base, the radial telescopic arm is telescopically mounted on the rotary swing arm, the vertical moving rod is vertically movable on the radial telescopic arm, and the detection sensor is mounted at the end of the vertical moving rod.

[0013] This invention also provides a gear grinding method using the above-mentioned dual-station internal gear generating grinding machine, comprising: clamping the workpiece to be processed on the workpiece spindle located at the loading and unloading station; detecting the grinding allowance of the workpiece through an automatic workpiece allowance allocation mechanism, and allocating grinding feed parameters according to the detection result; driving the workpiece exchange turntable to rotate, so that the workpiece spindle clamping the workpiece enters the grinding station; adjusting the rotation angle Ψ of the grinding wheel swing turntable according to the grinding wheel helix angle γ and the workpiece helix angle β, so that it satisfies the relationship: Ψ=γ-β; positioning the grinding wheel inside the internal gear workpiece, and performing generating grinding through the linkage of the B-axis, workpiece spindle, X-axis and Z-axis.

[0014] The present invention also provides a grinding wheel dressing method using the above-mentioned dual-station internal gear generating grinding machine, including in-machine dressing of the grinding wheel using a type I dressing tool, a type II dressing tool and / or a type III dressing tool, and dressing the outer circle of the grinding wheel by using a dressing diamond pen.

[0015] Compared with the prior art, the present invention has at least the following beneficial effects: First, the present invention adopts an internal gear generating grinding method, in which the grinding wheel and the workpiece mesh and rotate according to a set relationship, and relative sliding is generated by axial feed, which can improve the processing efficiency and processing accuracy of internal gears.

[0016] Secondly, the present invention adopts a dual-station structure, in which two workpiece spindles can be exchanged between the grinding station and the loading / unloading station, so that while one workpiece is being ground, the other workpiece can be unloaded, clamped and inspected for excess material, thereby significantly shortening auxiliary time and improving production cycle time.

[0017] Third, the present invention integrates a grinding wheel dressing mechanism, which can complete a variety of dressing methods in the machine to adapt to different tooth shapes, tooth directions and dressing requirements.

[0018] Fourth, the present invention is equipped with an automatic workpiece allowance allocation mechanism, which can detect the grinding allowance of the workpiece blank and automatically allocate grinding feed parameters according to the detection results, which is beneficial to improving the consistency of batch processing.

[0019] Fifth, this invention can be used for high-precision gear grinding of internal gear ring workpieces such as involute cylindrical internal gears and circular arc internal gears, and is suitable for mass production of high-precision internal gears in industries such as new energy vehicles and robot reducers. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of a dual-station internal gear generating grinding machine provided in an embodiment of the present invention; Figure 2 for Figure 1 The diagram shown illustrates the state of a gear grinding machine using a Type II dressing cutter to dress the grinding wheel. Figure 3 This is a schematic diagram of the grinding wheel dressing mechanism; Figure 4 A schematic diagram of the automatic workpiece allowance allocation mechanism; Figure 5 This is a schematic diagram of the angles Ψ, γ, and β during gear grinding using the gear grinding method of the present invention; Figure 6 This is a schematic diagram illustrating the working state of the grinding wheel and the workpiece during gear grinding using the gear grinding method of the present invention. Figure 7 This is a structural schematic diagram of a Class I dressing tool; Figure 8 This is a schematic diagram of the working state when dressing a grinding wheel using a Type I dressing tool; Figure 9 This is a structural diagram of a Class II dressing tool; Figure 10 This is a schematic diagram of the working state when dressing a grinding wheel using a Type II dressing tool; Figure 11 This is a structural schematic diagram of a Class III dressing tool; Figure 12 This is a schematic diagram illustrating the working state when dressing a grinding wheel using a Class III dressing tool; Figure 13 This is a schematic diagram illustrating the working state of dressing the outer circle of a grinding wheel using a diamond dressing tool.

[0021] The annotations in the attached figures are explained as follows: 1-Bed; 2-Slide plate; 3-Column; 4-Grinding wheel swing table; 5-Grinding wheel spindle; 6-Grinding wheel; 7-Workpiece exchange table; 8-Support column; 9-First workpiece spindle; 10-Second workpiece spindle; 11-Grinding wheel dressing mechanism; 111-Dressing spindle swing mechanism; 112-Grinding wheel dressing spindle; 113-Dressing diamond tool; 12-Automatic workpiece allowance distribution mechanism; 121-Support seat; 122-Rotating swing arm; 1221-Groove; 123-Radial telescopic arm; 1231-Slide groove; 124-Up and down moving rod; 125-Detection sensor; 126-First fastening screw; 127-Second fastening screw; 128-Rotary drive device; 13-Z-axis slide rail; 14-Workpiece; 15-Dressing tool. Detailed Implementation

[0022] To enable those skilled in the art to better understand the present invention, the specific embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0023] In this document, terms such as "upper," "lower," "inner," and "outer" are established based on the positional relationships shown in the accompanying drawings. Depending on the drawings, the corresponding positional relationships may also change. Therefore, they should not be interpreted as an absolute limitation on the scope of protection. Moreover, relational terms such as "first" and "second" are only used to distinguish one component from another that has the same name, and do not necessarily require or imply any such actual relationship or order between these components.

[0024] like Figure 1 As shown, this embodiment provides a dual-station internal gear generating grinding machine for high-precision generating grinding of an internal gear ring workpiece 14. The grinding machine includes a bed 1, a grinding wheel processing unit, a workpiece exchange turntable 7, a grinding wheel dressing mechanism 11, and a workpiece allowance automatic distribution mechanism 12.

[0025] The grinding wheel processing unit is located on one side above the bed 1, and the workpiece exchange turntable 7 is located on the other side above the bed 1, with the two arranged opposite each other. The grinding wheel processing unit is used to drive the grinding wheel 6 to perform grinding operations, and the workpiece exchange turntable 7 is used to carry the workpiece 14 and realize dual-station exchange.

[0026] Specifically, the grinding wheel machining unit includes a slide plate 2, a column 3, a grinding wheel oscillating turntable 4, and a grinding wheel spindle 5. The slide plate 2 is mounted on the bed 1 via a Y-axis guide rail and can move relative to the bed 1 in the Y direction. The column 3 is mounted on the slide plate 2 via an X-axis guide rail and can move relative to the slide plate 2 in the X direction. A vertical Z-axis slide rail 13 is provided on the side of the column 3 facing the workpiece exchange turntable 7, and the grinding wheel oscillating turntable 4 is mounted on the column 3 via the Z-axis slide rail 13 and can move in the Z direction.

[0027] The grinding wheel spindle 5 is mounted on the grinding wheel oscillating turntable 4. The grinding wheel spindle 5 is used to mount the grinding wheel 6 and can drive the grinding wheel 6 to rotate at high speed around its own axis. The grinding wheel oscillating turntable 4 has a vertical structure and can drive the grinding wheel spindle 5 to oscillate, so that the axis of the grinding wheel 6 and the axis of the workpiece 14 form a cross angle.

[0028] With the above structure, the grinding wheel 6 can achieve linear coordinate movement in three directions: X, Y and Z. At the same time, the angle can be adjusted by the grinding wheel swing turntable 4, thereby meeting the spatial movement requirements of internal gear generating grinding.

[0029] like Figure 1 As shown, the workpiece exchange rotary table 7 is mounted above the bed 1 and located on the opposite side of the grinding wheel spindle 5. A support column 8 is provided in the center of the workpiece exchange rotary table 7. The first workpiece spindle 9 and the second workpiece spindle 10 are symmetrically mounted on the workpiece exchange rotary table 7 at 180° angles and are located on both sides of the support column 8, respectively.

[0030] The workpiece exchange turntable 7 can achieve forward and reverse rotation within the range of 0° to 180° through the drive mechanism, thereby driving the first workpiece spindle 9 and the second workpiece spindle 10 to exchange between the grinding station and the loading and unloading station.

[0031] In one embodiment, the workpiece exchange turntable 7 is directly driven by a torque motor. In another embodiment, the workpiece exchange turntable 7 is driven by a motor through a gear reduction mechanism. Both of these driving methods can achieve the workstation exchange function.

[0032] While workpiece 14 on the first workpiece spindle 9 is being processed in the grinding station, the second workpiece spindle 10 can be in the loading / unloading station for finished product unloading, blank clamping, and allowance inspection. After workpiece 14 on the first workpiece spindle 9 is processed, the workpiece exchange turntable 7 rotates 180°, causing the second workpiece spindle 10 to enter the grinding station, while the first workpiece spindle 9 enters the loading / unloading station. This allows for parallel grinding and loading / unloading operations, improving processing efficiency.

[0033] like Figure 2 and Figure 3 As shown, the grinding wheel dressing mechanism 11 is mounted on the workpiece exchange turntable 7. The grinding wheel dressing mechanism 11 includes a dressing spindle swing mechanism 111 and a grinding wheel dressing spindle 112.

[0034] The dressing spindle oscillation mechanism 111 is mounted on the outer wall of one end of the support column 8. The grinding wheel dressing spindle 112 is mounted on the dressing spindle oscillation mechanism 111 and is arranged vertically. The grinding wheel dressing spindle 112 can drive the dressing tool 15 to rotate around its own axis.

[0035] The rotation axis of the dressing spindle swing mechanism 111 is perpendicular to the axis of the grinding wheel dressing spindle 112. The dressing spindle swing mechanism 111 can drive the grinding wheel dressing spindle 112 to swing within a range of ±90° to meet the dressing requirements of different dressing tools 15 and different grinding wheel tooth profiles.

[0036] The grinding wheel dressing mechanism 11 also includes a dressing diamond pen 113. The dressing diamond pen 113 is mounted on the side wall of the grinding wheel dressing spindle 112, with its axis perpendicular to the axis of the grinding wheel dressing spindle 112, and its working front end is hemispherical. The dressing diamond pen 113 is mainly used to dress the outer diameter of the grinding wheel 6, forming the required drum-shaped outer diameter of the grinding wheel.

[0037] like Figure 4 As shown, the automatic workpiece allowance distribution mechanism 12 includes a support base 121, a rotating swing arm 122, a radial telescopic arm 123, an up-and-down moving rod 124, and a detection sensor 125.

[0038] The support base 121 is mounted above the bed 1 and located beside the workpiece exchange turntable 7. The rotary swing arm 122 is mounted on the upper end of the support base 121 via a rotating shaft and is driven to rotate by a rotary drive device 128. The rotary swing arm 122 has a detection position and an avoidance position.

[0039] A groove 1221 is provided inside the rotating arm 122, and a radial telescopic arm 123 is installed in the groove 1221 and can extend and retract along the groove 1221. A first fastening screw 126 is provided on the radial telescopic arm 123, and the end of the first fastening screw 126 can abut against the bottom surface of the groove 1221, thereby locking the radial telescopic arm 123 relative to the rotating arm 122. When it is necessary to accommodate workpieces 14 of different diameters, the first fastening screw 126 can be loosened, the extension length of the radial telescopic arm 123 can be adjusted, and then the first fastening screw 126 can be tightened to fix it.

[0040] The radial telescopic arm 123 has a groove 1231 at its end, and the extension direction of the groove 1231 is perpendicular to the extension direction of the recess 1221. The vertical moving rod 124 is slidably mounted in the groove 1231 and locked by the second fastening screw 127. When it is necessary to accommodate workpieces 14 with different tooth widths and heights, the second fastening screw 127 can be loosened, the position of the vertical moving rod 124 can be adjusted, and then the second fastening screw 127 can be tightened to fix it.

[0041] The detection sensor 125 is mounted at the end of the vertical moving rod 124. During operation, the rotary drive device 128 drives the rotary arm 122 to rotate to the horizontal detection position. The detection sensor 125 detects the grinding allowance of the workpiece blank. The machine tool control system automatically calculates and allocates the target grinding feed parameters based on the detection results. After the detection is completed, the rotary arm 122 rotates to the vertical avoidance position to avoid interfering with workpiece exchange and grinding.

[0042] The dual-station internal gear generating grinding machine of this embodiment is a vertical dual-station structure, equipped with A-axis, B-axis, B1-axis, A1-axis, C1-axis, C2-axis, C3-axis, X-axis, Y-axis and Z-axis.

[0043] Among them, A-axis is the grinding wheel oscillating turntable axis; B-axis is the grinding wheel spindle; B1-axis is the dressing spindle; A1-axis is the dressing oscillating axis; C1-axis and C2-axis are the rotation axes of the first workpiece spindle 9 and the second workpiece spindle 10, respectively; C3-axis is the rotation axis of the workpiece exchange turntable 7; X-axis is the radial feed axis; Y-axis is the tangential feed axis; and Z-axis is the axial feed axis.

[0044] Through the above-mentioned multi-axis linkage control, the present invention can realize internal gear generating grinding, tooth direction modification, tooth profile modification, and grinding wheel dressing in machine.

[0045] like Figure 5 and Figure 6 As shown, the present invention also provides a gear grinding method using the above-mentioned dual-station internal gear generating grinding machine.

[0046] First, the workpiece 14 to be processed is clamped on the workpiece spindle located at the loading and unloading station. Then, the automatic workpiece allowance allocation mechanism 12 detects the grinding allowance of the gear blank of the workpiece 14 and sends the detection result to the control system. The control system allocates grinding feed parameters according to the detection result.

[0047] Then, drive the workpiece exchange turntable 7 to rotate, so that the workpiece spindle with workpiece 14 clamped on it enters the grinding station.

[0048] During gear grinding, the rotation angle Ψ of the grinding wheel oscillating turntable 4 is adjusted according to the helix angle γ of the grinding wheel and the helix angle β of the workpiece, so that the three satisfy: Ψ=γ-β.

[0049] Among them, the rotation direction of the grinding wheel and the workpiece is defined as positive for right-hand rotation, negative for left-hand rotation, and zero for straight teeth; the rotation angle of the grinding wheel oscillating turntable 4 is defined as positive for right-hand rotation, negative for left-hand rotation, and zero for vertical state.

[0050] During gear grinding, the grinding wheel 6 is located inside the internal gear workpiece 14, and the B-axis, the workpiece spindle entering the grinding station, the X-axis, and the Z-axis perform coordinated grinding. Specifically, the B-axis and the workpiece spindle rotate synchronously at high speed according to a set tooth ratio; the Z-axis moves along the tooth width direction and can reciprocate multiple times; the workpiece spindle synchronously follows the Z-axis in a helical motion; and the X-axis moves radially inward along the gear as the Z-axis position changes, thereby forming different tooth profiles.

[0051] This invention can employ two grinding wheel solutions: The first option involves using a standard corundum grinding wheel mounted on the grinding wheel spindle 5, and then precision dressing it in-machine using the grinding wheel dressing mechanism 11 to achieve the required tooth profile and direction before grinding the internal gear. This option is highly versatile due to the dressable grinding wheel, making it suitable for diverse, small-batch, or flexible processing needs.

[0052] The second option is to use a shaped grinding wheel with a metal substrate and a special coating, such as a CBN material grinding wheel, which is mounted on the grinding wheel spindle 5 to machine internal gears. This grinding wheel can be designed and manufactured to meet the tooth profile and tooth direction accuracy requirements of the workpiece 14 one-to-one, and can be directly ground without machine dressing. It is suitable for single-product, mass production and helps to improve tool life and tooth surface waviness stability.

[0053] The present invention also provides an in-machine dressing method for grinding wheels, wherein at least one of a type I dressing tool, a type II dressing tool, and a type III dressing tool is used to dress the grinding wheel 6.

[0054] like Figure 7 and Figure 8 As shown, the Type I dressing tool is a cylindrical toothed dressing tool. Utilizing the external meshing principle of gear transmission and in conjunction with the CNC coordinate axes of the machine tool, the Type I dressing tool can change the tooth shape of the grinding wheel 6, thereby performing micro-adjustments on the tooth precision of the workpiece 14. It is suitable for diverse toothed workpieces with different dressing requirements.

[0055] During dressing, the grinding wheel oscillating turntable 4 is in a vertical position, and the workpiece exchange turntable 7 rotates 90° clockwise, so that the grinding wheel dressing spindle 112 is in the position directly opposite the grinding wheel spindle 5. Based on the helix angle δ of the type I dressing tool and the helix angle γ of the grinding wheel, the rotation angle Σ is adjusted by the dressing spindle oscillating mechanism 111 to ensure that the three conditions are met: Σ=γ±δ.

[0056] Among them, the helix angle δ of the type I dressing tool is positive when the helix angle γ of the grinding wheel is in the same direction, and negative when the helix angles are opposite.

[0057] During dressing, multiple axes—X, Y, Z, A1, B, and B1—work in tandem. Specifically, the B and B1 axes rotate synchronously at high speed according to a set tooth ratio; the Z-axis moves along the grinding wheel tooth width direction, repeating multiple times; the B1 axis follows the Z-axis in a helical motion; the X-axis feeds according to the Z-axis position, creating different grinding wheel tooth profiles; the A1 axis adjusts its angle according to the Z-axis position, creating different tooth pressure angles; and the Y-axis compensates for tool center position offsets as the A1 axis angle changes.

[0058] like Figure 9 and Figure 10 As shown, Type II dressing tools are disc-shaped dressing tools. Type II dressing tools use a forming meshing principle and work in conjunction with the CNC coordinate axes of the machine tool for sanding. The tool cost and manufacturing difficulty are relatively low.

[0059] During dressing, the grinding wheel swing turntable 4 is in a vertical position, and the workpiece exchange turntable 7 rotates 90° clockwise, so that the grinding wheel dressing spindle 112 is in the position directly opposite the grinding wheel spindle 5. According to the grinding wheel helix angle γ, the dressing spindle swing mechanism 111 rotates to 90°-γ, so that the disc-type type II dressing tool enters the grinding wheel tooth groove.

[0060] During dressing, multiple axes—X, Y, Z, A1, B, and B1—work in tandem. The B1 axis rotates at a fixed speed; the Z-axis moves along the grinding wheel tooth width direction, repeating multiple times; the B-axis follows the Z-axis in a helical motion; the X-axis feeds according to the Z-axis position, creating different grinding wheel tooth profiles; the A1 axis adjusts its angle according to the Z-axis position, creating different tooth pressure angles; and the Y-axis compensates for tool center position offsets as the A1 axis angle changes. After dressing each tooth, the B-axis performs a tooth-splitting motion, switching to the next tooth to continue dressing, until all teeth are dressed.

[0061] like Figure 11 and Figure 12 As shown, Type III dressing tools are ring-shaped toothed dressing tools. Type III dressing tools utilize the internal meshing principle of gear transmission, working in conjunction with the CNC coordinate axes of the machine tool to perform sand removal, achieving high dressing accuracy.

[0062] The tooth profile, tooth direction and other geometric shapes of the Class III dressing tool and the shaping requirements are consistent with the workpiece 14 being processed, and the tooth surface of the Class III dressing tool can be coated with a special coating, such as a diamond coating.

[0063] During sand trimming, the X-axis, Z-axis, B-axis, and C1-axis work in tandem. Specifically, the B-axis and C1-axis rotate synchronously at high speed according to the set tooth ratio; the Z-axis moves along the tooth width direction and can reciprocate multiple times; the C1-axis moves in a spiral motion synchronously with the Z-axis; after each Z-axis completes a moving motion, the X-axis performs a feed motion until the preset tooth depth is reached.

[0064] like Figure 13 As shown, the aforementioned Type I dressing tool, Type II dressing tool and Type III dressing tool are mainly used to dress the tooth grooves of the grinding wheel, and the dressing diamond pen 113 is used to dress the outer circle of the grinding wheel 6.

[0065] When dressing the outer diameter of the grinding wheel, the X, Y, Z and B1 axes of the machine tool move in tandem to create the required trajectory on the outer diameter of the grinding wheel 6, thus obtaining the drum-shaped outer diameter of the grinding wheel. The drum-shaped outer diameter of the grinding wheel can solve the problem of interference between the grinding wheel tooth tip and the workpiece tooth tip when there is an axial angle between the grinding wheel axis and the workpiece axis during gear grinding.

[0066] When the dual-station internal gear generating grinding machine of the present invention is working, the first workpiece spindle 9 is located at the grinding station, and the second workpiece spindle 10 is located at the loading and unloading station. The workpiece 14 on the first workpiece spindle 9 is ground, while the finished product is unloaded, the blank is clamped, and the workpiece allowance is detected at the second workpiece spindle 10.

[0067] After the workpiece 14 on the first workpiece spindle 9 is ground, the workpiece exchange turntable 7 rotates 180°, allowing the second workpiece spindle 10 to enter the grinding station, and the first workpiece spindle 9 to enter the loading / unloading station. Subsequently, the workpiece 14 on the second workpiece spindle 10 begins grinding, the finished product on the first workpiece spindle 9 is unloaded and a new workpiece 14 to be processed is clamped, and workpiece allowance is simultaneously checked. This process is repeated cyclically, significantly improving equipment utilization and processing efficiency.

[0068] After grinding a certain number of workpieces 14, when the grinding wheel 6 becomes dull and needs dressing, the workpiece exchange turntable 7 rotates 90° clockwise to align the grinding wheel dressing spindle 112 with the grinding wheel spindle 5 in the X direction. Then, based on the grinding wheel helix angle and the type of dressing tool, the angle of the dressing spindle oscillation mechanism 111 is adjusted to engage the grinding wheel 6 with the dressing tool for dressing. After dressing, the workpiece exchange turntable 7 rotates 90° counterclockwise to re-enter the grinding position and continue the cyclic grinding process.

[0069] Without departing from the concept of the invention, the structure of the present invention can be modified in various ways. For example, in some application scenarios, one of the workpiece spindles can be eliminated, transforming the dual-station internal gear generating and grinding machine into a single-station internal gear generating and grinding machine.

[0070] For example, the grinding wheel dressing spindle 112 and the dressing spindle swing mechanism 111 may not be installed on the workpiece exchange turntable 7, but can be directly installed in a fixed position on the bed 1, as long as the grinding wheel 6 can be dressed on the machine.

[0071] For example, the installation positions of the X, Y, and Z axes can be adjusted according to the overall layout of the machine tool. For instance, the Y axis can be set in front of the grinding wheel oscillating turntable 4, and the X axis can be directly arranged on the bed 1, as long as the radial, tangential, and axial feed movements of the grinding wheel 6 relative to the workpiece 14 can be achieved.

[0072] The present invention provides a detailed description of a dual-station internal gear generating grinding machine and its processing method. Specific examples have been used to illustrate the principles and implementation methods of the invention. The descriptions of these embodiments are merely for the purpose of helping to understand the core ideas of the invention. It should be noted that those skilled in the art can make various improvements and modifications to the invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A dual-station internal gear generating and grinding machine, characterized in that, include: Bed frame (1); A grinding wheel processing unit is mounted on the bed (1). The grinding wheel processing unit includes a grinding wheel oscillating turntable (4) and a grinding wheel spindle (5) mounted on the grinding wheel oscillating turntable (4). The grinding wheel spindle (5) is used to mount the grinding wheel (6). The grinding wheel oscillating turntable (4) is used to drive the grinding wheel spindle (5) to oscillate so that the axis of the grinding wheel (6) and the axis of the workpiece (14) form a cross angle. A workpiece exchange turntable (7) is set on the bed (1) and arranged opposite to the grinding wheel processing unit. A first workpiece spindle (9) and a second workpiece spindle (10) are provided on the workpiece exchange turntable (7). The workpiece exchange turntable (7) can rotate so that the first workpiece spindle (9) and the second workpiece spindle (10) can be exchanged between the grinding station and the loading and unloading station. A grinding wheel dressing mechanism (11) is used to perform in-machine dressing of the grinding wheel (6); and The workpiece allowance automatic allocation mechanism (12) is used to detect the grinding allowance of the workpiece (14) and allocate grinding feed parameters according to the detection result.

2. The dual-station internal gear generating grinding machine according to claim 1, characterized in that, The grinding wheel processing unit also includes a slide plate (2) and a column (3). The slide plate (2) is movably mounted on the bed (1) along the Y direction, the column (3) is movably mounted on the slide plate (2) along the X direction, and the grinding wheel swing turntable (4) is movably mounted on the column (3) along the Z direction, so as to drive the grinding wheel (6) to achieve linear coordinate movement in the X, Y and Z directions.

3. The dual-station internal gear generating grinding machine according to claim 2, characterized in that, The slide plate (2) is mounted on the bed (1) via the Y-axis guide rail, the column (3) is mounted on the slide plate (2) via the X-axis guide rail, the column (3) is provided with a Z-axis slide rail (13) on the side facing the workpiece exchange turntable (7), and the grinding wheel swing turntable (4) is mounted on the column (3) via the Z-axis slide rail (13).

4. The dual-station internal gear generating grinding machine according to claim 1, characterized in that, The grinding wheel oscillating turntable (4) is a vertical oscillating turntable. The grinding wheel oscillating turntable (4) corresponds to the machine tool A axis, and the grinding wheel spindle (5) corresponds to the machine tool B axis. The grinding wheel spindle (5) can drive the grinding wheel (6) to rotate around its own axis.

5. The dual-station internal gear generating grinding machine according to claim 1, characterized in that, The workpiece exchange turntable (7) has a support column (8) in the center. The first workpiece spindle (9) and the second workpiece spindle (10) are symmetrically arranged at 180° on the workpiece exchange turntable (7) and are located on both sides of the support column (8).

6. The dual-station internal gear generating grinding machine according to claim 5, characterized in that, The workpiece exchange turntable (7) can rotate in both directions within a range of 0° to 180° to drive the first workpiece spindle (9) and the second workpiece spindle (10) to exchange between the grinding station and the loading / unloading station.

7. The dual-station internal gear generating grinding machine according to claim 6, characterized in that, The workpiece exchange turntable (7) is directly driven by a torque motor or by a motor via a gear reduction mechanism.

8. The dual-station internal gear generating grinding machine according to claim 5, characterized in that, The grinding wheel dressing mechanism (11) is installed on the workpiece exchange turntable (7). The grinding wheel dressing mechanism (11) includes a dressing spindle swing mechanism (111) and a grinding wheel dressing spindle (112). The dressing spindle swing mechanism (111) is installed on the outer wall of one end of the support column (8), and the grinding wheel dressing spindle (112) is installed on the dressing spindle swing mechanism (111).

9. The dual-station internal gear generating grinding machine according to claim 8, characterized in that, The grinding wheel dressing spindle (112) is arranged vertically. The grinding wheel dressing spindle (112) corresponds to the B1 axis of the machine tool and can drive the dressing tool to rotate around its own axis. The dressing spindle swing mechanism (111) corresponds to the A1 axis of the machine tool. The rotation axis of the dressing spindle swing mechanism (111) is perpendicular to the axis of the grinding wheel dressing spindle (112), and the dressing spindle swing mechanism (111) can drive the grinding wheel dressing spindle (112) to swing within a range of ±90°.

10. The dual-station internal gear generating grinding machine according to claim 8, characterized in that, The grinding wheel dressing mechanism (11) also includes a dressing diamond pen (113), which is installed on the side wall of the grinding wheel dressing spindle (112). The axis of the dressing diamond pen (113) is perpendicular to the axis of the grinding wheel dressing spindle (112), and the working front end of the dressing diamond pen (113) is hemispherical.

11. The dual-station internal gear generating grinding machine according to claim 1, characterized in that, The automatic workpiece allowance distribution mechanism (12) includes a support base (121), a rotary swing arm (122), a radial telescopic arm (123), a vertical moving rod (124), and a detection sensor (125). The support base (121) is mounted on the bed (1). The rotary swing arm (122) is rotatably mounted on the support base (121). The radial telescopic arm (123) is telescopically mounted on the rotary swing arm (122). The vertical moving rod (124) is vertically movable on the radial telescopic arm (123). The detection sensor (125) is mounted at the end of the vertical moving rod (124).

12. The dual-station internal gear generating grinding machine according to claim 11, characterized in that, The rotating swing arm (122) is provided with a groove (1221), the radial telescopic arm (123) is installed in the groove (1221) and guided by the groove (1221), and the radial telescopic arm (123) is provided with a first fastening screw (126) for locking the radial telescopic arm (123).

13. The dual-station internal gear generating grinding machine according to claim 12, characterized in that, The end of the radial telescopic arm (123) is provided with a groove (1231), the extension direction of the groove (1231) is perpendicular to the extension direction of the groove (1221), and the up and down moving rod (124) is slidably installed in the groove (1231) and locked by the second fastening screw (127).

14. The dual-station internal gear generating grinding machine according to claim 11, characterized in that, The rotating arm (122) has a detection position and a avoidance position. In the detection position, the rotating arm (122) is in a horizontal state, so that the detection sensor (125) can detect the grinding allowance of the gear blank of the workpiece (14). In the avoidance position, the rotating arm (122) is in a vertical state to avoid the workpiece exchange turntable (7) and / or the workpiece (14).

15. The dual-station internal gear generating grinding machine according to claim 10, characterized in that, The dual-station internal gear generating grinding machine is a vertical dual-station structure, equipped with axes A, B, B1, A1, C1, C2, C3, X, Y, and Z. Among them, axis A is the grinding wheel oscillating turntable axis, axis B is the grinding wheel spindle, axis B1 is the dressing spindle, axis A1 is the dressing oscillating axis, axes C1 and C2 are two sets of workpiece spindles respectively, axis C3 is the workpiece exchange turntable axis, axis X is the radial feed axis, axis Y is the tangential feed axis, and axis Z is the axial feed axis.

16. A gear grinding method, used in the dual-station internal gear generating gear grinding machine as described in claim 15, characterized in that, include: The workpiece (14) to be processed is clamped on the workpiece spindle located at the loading and unloading station; The grinding allowance of the workpiece (14) is detected by the workpiece allowance automatic allocation mechanism (12), and the grinding feed parameters are allocated according to the detection results. Drive the workpiece exchange turntable (7) to rotate, so that the workpiece spindle with the workpiece (14) clamped on it enters the grinding station; Adjust the rotation angle Ψ of the grinding wheel oscillating turntable (4) according to the grinding wheel helix angle γ and the workpiece helix angle β, so that it satisfies the relationship: Ψ=γ-β; The grinding wheel (6) is positioned inside the internal gear workpiece (14), and generating grinding is performed through the linkage of the B axis, workpiece spindle, X axis and Z axis.

17. The gear grinding method according to claim 16, characterized in that, During the gear grinding process, the B-axis and the workpiece spindle that enters the grinding station rotate synchronously according to the set tooth ratio. The Z-axis moves along the tooth width direction, and the workpiece spindle follows the Z-axis in a helical motion. The X-axis moves radially as the position of the Z-axis changes, so as to form tooth profile modification.

18. The gear grinding method according to claim 16, characterized in that, The rotation direction of the grinding wheel and the workpiece is defined as positive for right-hand rotation, negative for left-hand rotation, and zero for straight teeth. The rotation angle of the grinding wheel swing turntable (4) is defined as positive for right-hand rotation, negative for left-hand rotation, and zero for vertical state.

19. The gear grinding method according to claim 16, characterized in that, The grinding wheel (6) is a common corundum grinding wheel. The common corundum grinding wheel is dressed to a preset tooth shape and tooth direction by the grinding wheel dressing mechanism (11) and then ground. Alternatively, the grinding wheel (6) is a metal-based molded abrasive with a coating. The tooth shape and tooth direction of the molded abrasive correspond to the workpiece (14) and grinding can be performed without on-machine dressing.

20. A grinding wheel dressing method, used in the dual-station internal gear generating grinding machine as described in claim 15, characterized in that, Including at least one of the following repair methods: First dressing method: Install a cylindrical toothed type I dressing tool on the grinding wheel dressing spindle (112), rotate the workpiece exchange turntable (7) to the dressing position, and perform external meshing dressing on the tooth groove of the grinding wheel (6) through the linkage between the grinding wheel dressing spindle (112) and the grinding wheel spindle (5). The second dressing method is to install a disc-type type II dressing cutter on the grinding wheel dressing spindle (112), so that the disc-type type II dressing cutter enters the tooth groove of the grinding wheel (6), and the grinding wheel (6) is dressed tooth by tooth through multi-axis linkage and tooth-dividing motion. The third dressing method: Install a ring-shaped toothed type III dressing tool on the first workpiece spindle (9) or the second workpiece spindle (10), and dress the grinding wheel (6) through the internal meshing motion of the type III dressing tool and the grinding wheel (6).

21. The grinding wheel dressing method according to claim 20, characterized in that, In the first dressing method, the grinding wheel swing turntable (4) is in a vertical state during dressing, and the workpiece exchange turntable (7) rotates 90° so that the grinding wheel dressing spindle (112) is directly opposite to the grinding wheel spindle (5). The rotation angle Σ of the dressing spindle swing mechanism (111) is adjusted according to the helix angle δ of the type I dressing tool and the helix angle γ of the grinding wheel so that it satisfies the relationship: Σ=γ±δ, where the positive value is taken when the rotation direction of the type I dressing tool and the grinding wheel (6) is the same, and the negative value is taken when the rotation direction of the type I dressing tool and the grinding wheel (6) is opposite.

22. The grinding wheel dressing method according to claim 21, characterized in that, In the first dressing method, dressing is performed by linkage of the X-axis, Y-axis, Z-axis, A1-axis, B-axis, and B1-axis. The B-axis and B1-axis rotate synchronously according to a set tooth ratio, the Z-axis moves along the tooth width direction of the grinding wheel, the B1-axis follows the Z-axis in a helical motion, the X-axis feeds as the Z-axis position changes, the A1-axis adjusts the axis intersection angle as the Z-axis position changes, and the Y-axis compensates for the offset of the tool center position as the A1-axis angle changes.

23. The grinding wheel dressing method according to claim 20, characterized in that, In the second dressing method, the grinding wheel swing turntable (4) is in a vertical state during dressing, and the workpiece exchange turntable (7) rotates 90° so that the grinding wheel dressing spindle (112) is aligned with the grinding wheel spindle (5). The angle of the dressing spindle swing mechanism (111) is adjusted to 90°-γ according to the grinding wheel helix angle γ so that the disc type II dressing tool enters the grinding wheel tooth groove.

24. The grinding wheel dressing method according to claim 23, characterized in that, In the second dressing method, dressing is performed by the linkage of the X-axis, Y-axis, Z-axis, A1-axis, B-axis and B1-axis. The B1-axis rotates at a fixed speed, the Z-axis moves along the tooth width of the grinding wheel, the B-axis follows the Z-axis in a spiral motion, the X-axis feeds as the Z-axis position changes, the A1-axis adjusts the axis angle as the Z-axis position changes, and the Y-axis compensates for the offset of the tool center position as the A1-axis angle changes. After dressing one tooth of the grinding wheel (6), the B-axis performs a tooth splitting motion until all teeth are dressed.

25. The grinding wheel dressing method according to claim 20, characterized in that, In the third dressing method, the tooth shape, tooth direction and dressing requirements of the type III dressing tool are consistent with the workpiece (14) being processed, and the tooth surface of the type III dressing tool is coated with a diamond coating.

26. The grinding wheel dressing method according to claim 25, characterized in that, In the third dressing method, the dressing process is carried out by the X-axis, Z-axis, B-axis and C1-axis or C2-axis in a coordinated manner. The B-axis and C1-axis rotate synchronously at high speed with a preset tooth ratio. The Z-axis moves along the tooth width direction and can repeat multiple times. The C1-axis also moves in a spiral motion synchronously with the Z-axis. After the Z-axis completes one movement, the X-axis moves once until the preset tooth depth is reached.

27. The grinding wheel dressing method according to claim 20, characterized in that, It also includes the step of dressing the outer circle of the grinding wheel (6) using a dressing diamond pen (113). By linking the X-axis, Y-axis, Z-axis and B1-axis, the dressing diamond pen (113) is dressed to form the outer circle of the drum-shaped grinding wheel, so as to avoid interference between the grinding wheel tooth tip and the workpiece tooth tip during the grinding process.

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